HPL E Frenco GmbH

Transcription

1 HPL E Frenco GmbH

2 Indispensable for Constructional Feasibility! Go and not go gauges are types of spline gauges. They are described in several German and foreign standards, as well as in the international standard ISO All these standards differ from one another and are neither comprehensive nor technically up-to-date. Spline gauges provide a quick method of inspecting involute splines, serration splines and straight sided splines. Go gauges are still indispensable for inspecting constructional feasibility. Not go gauges, on the other hand, only represent a limited means of inspection. Direct size inspection takes priority over not go gauges. Plug gauges go not go Involute flanks Serrated flanks Straight flanks Ring gauges go not go Involute flanks Serrated flanks Straight flanks 2

3 Technical Standard Spline gauges are described in several German and foreign standards as well as in the international standard ISO All these standards differ from one another and are neither comprehensive nor technically up-to-date. FRENCO s specialist knowledge facilitates more advanced diagnosis than in the currently applicable standards. At the same time, FRENCO is working towards adapting the existing standards in the relevant committees. Spline gauges are usually ordered according to standards or by part number. When comparing prices, references to the relevant standards are inadequate, as they do not satisfy the exacting demands of ISO 9000ff. These are defined below as characteristics, such that they may also be applied by certified companies. Gauge Drawings + Gauge drawings also contain a worn dimension for not go gauges + Not go gauge plugs have a complete pilot diameter + Ring gauges should be provided with protection against hand warmth + Modification statuses are noted on gauge drawings with dates + Repeat orders are assigned to the modification statuses + The gauge drawing includes a measuring pin change factor (AF1=) + Gauge drawings include wear limits for individual form deviations Gauge Design + All spline gauges are clearly and permanently labeled with profile data, user identification number, manufacturer s drawing and drawing number, material, serial number and date of manufacture. + Special steels are available for prolonged durability, reduction of test equipment monitoring costs or reduced manufacturing or wear tolerances. These have a higher alloy content and hardness. + Spline gauges are reusable. Worn gauges will be accepted against a charge. + Special delivery times down to a few days are possible in the case of urgent requirements. + Go gauges are green for pitch circles up to 50 mm, not go gauges are marked red. Quality + All spline gauges are supplied with a full calibrated certificate, including graphs of all individual form deviations. They comply with the requirements of ISO 9000ff and thus completely replace the incoming goods inspection. Exceptions are possible upon request. + Agreement B applies as the acceptance condition for maintaining the tolerance limits with prioritization according to OFD 11, page Directions are available for wear inspection at the user s premises. + War inspection of spline gauges is offered as a service Complaints + In the case of complaints, the user s testing costs arising will be reimbursed up to the test certificate price limit. + Claims for damages are possible if a calibration certificate was ordered. + Any remanufacture or rework will take place within shortest possible time. + A 5-year guarantee against material faults is provided. Should a material fault be ascertained within this period, reworking will take place at no charge. 3

4 D D The Frenco INO System The INO system is a FRENCO internal standard for the external dimensional measurement of spline gauges. National and international standards were taken into consideration in its development and it represents an average of the dimensions specified in these standards. The construction considers the recyclability and manufacturability of the extremely wearresistant material HX. go Gut L1 Lehrdorne gage plugs not go Ausschuß L2 gage Lehrringe rings go Gut Ausschuß not go L3 L4 The tabulated dimensions for Frenco INO apply for all splines with involute and serration flanks. Gut L1 Lehrdorne Ausschuß L2 Lehrringe Gut Ausschuß L3 L4 Frenco INO-L is used as standard for go straight flank gauges. INO-L dimensions are available for oversize gauges on request. FRENCO INO FRENCO INO-L Dimension Pitch circle D L1 L2 L3 L4 L1 L2 L3 L

5 Selection of Materials The content of chromium and vanadium alloy, as well as the hardness of the material, determine the wear resistance of the spline gauge. The time intervals between wear inspections depend on wear resistance, which means that highly wear resistant materials allow the monitoring periods to be significantly extended; this often more than compensates for the higher manufacturing costs. [%] wear resistance CS SX 1 HX Werkstoff Art % C % V % Cr HRc CS Chrome steel 1,5 0, SX low alloy powder steel ASP 23 1, HX high alloy powder steel 3,

6 Delivery Delivery capacity is restricted as a consequence of the technical niche position and the resulting limited availability of trained staff and technical equipment. Delivery times are therefore subject to fluctuations depending on demand and can only be arranged on a waiting list basis. Gauge Drawings The quoted prices for spline gauges always include the generation of comprehensive gauge drawings (also available in electronic form), as well as a full test certificate of the new condition from the FRENCO calibration laboratory. DIN 5480 N 23 x 1,75 x 12 x 30 x 9H LQ4 Spline plug gauge Go plug gauge Not go plug gauge Number of teeth Module 1,75 Pressure angle 30 Pitch circle 21,000 Base circle 18,1865 Root circle 18,9 Form 19,40 Tip 22,720 0,033 22,545 0,033 Measuring pin 3,50 (AF1=2,6) Thooth thickness 2, ,007 2,8550 0,0035 Dimension over 2 pins 26, , ,6466 0,0049 Worn tooth thickness 2,7810 2,8480 Worn dimension over pins 26, ,6368 Reference axis = axis of profile new condition wear limit Total profile deviation Runout deviation Total pitch deviation Total helix trace deviation

7 Inspection in New Condition Characteristic Measurement uncertainty Measurement methods Damage Visual gear inspection Damage or rust is not permissible Notes Identity Visual inspection of labeling The labeling must include profile data, standard designation, date of manufacture and manufacturer s mark Tooth thickness of plug gauge to Auxiliary dimension over 2 pins Auxiliary dimension over 2 measuring balls with Abbe measurement methods each over 90 in front, middle, rear Measuring force less than 1.5 N Measuring pins must be rubbed Roundness deviation of the measuring pins or measuring balls: max Deviation of the measuring pins or measuring balls from the nominal dimension: max Nominal dimension correction with actual measuring pin dimension is necessary. Additionally for tooth space of Ring gauge to Size between pins by the use of gauge blocks. (see OFE 09) With master plug gauge see OFR 12. The gauge blocks having the actual dimension must not show any tilt clearance between both measuring pins; it must however still be axially slidable without sticking. Tip Root circle Abbe measurement methods 3D measurement machines Form circle Analytical inspection machines -3D inspection machines The root circle is not checked along with flank centering. Check via roll distance or roll angle Individual form deviations Total profile Total lead Single index Total index Runout Roundness Analytical inspection machines - inspection machines with rotary stage Profile and lead at 4 right and left flanks Only for go gauges: Index of all tooth flanks Reference axis pitch circle axis or with alignment diameter (lower priority) The measurement uncertainty of is theoretically too large, but practically not better attainable. As a result of the unfavorable relationship between gauge tolerances and the smallest attainable measuring uncertainty, spine gauges can only be rejected if the measured dimension lies outside the tolerance limits extended by the measurement uncertainty. (non-conformance zone according to DIN EN ISO ). In the absence of explicit references to other regulations or agreements, agreement B applies with designation of priority according to the Frenco definition OFD 10, page 18. 7

8 Periodical Wear Inspection is necessary Spline gauges are subject to wear during their use. A wear tolerance with a permissible wear limit for the worn dimension is designated for this purpose. Once the wear limit has been reached, these gauges are to be selected out.in many instances the wear is not uniformly distributed. Testing of the individual form deviations at prescribed time intervals is therefore necessary (also see OFE 05 Wear limit of not go spline gauges ). The table below gives reference values for the test cycles of the necessary monitoring of spline gauges. These values are only rough estimates, as wear produces different effects in every case. The anticipated lifespan, expressed in the number of parts inspections to be performed, serves as the basis for the monitoring cycle. After 25% of the total estimated life-span there should be a size inspection over or between pins; after 50% an inspection of dimensions and individual form deviation. Gauge material Number of material inspections hardened unhardened chrome steel estimated life-span HRc size inspections per piece (1.2379) size and form inspections per piece Low alloy powder HSS HRc (ASP) estimated life-span size inspections per piece size and form inspections per piece High alloy powder HSS HRc (HX) estimated life-span size inspections per piece size and form inspections per piece The estimated life-span of a gauge should be adjusted from experience according to the actual conditions. If the number of parts inspections is so low that a wear inspection of gauges is only required after a year, it is recommended to assign a period of a year for the size inspection and two years for the size and form inspection. If in doubt, a size and form inspection should always be carried out for critical parts and for safety-relevant components. For additional tolerances of single deviations from the tolerances in new condition see the next but one page. 8

9 Wear Inspection of Spline Gauges Characteristic Measurement uncertainty Measurement methods Damage Visual inspection of the gear and spline small damage may be removed with a grinding stone Identity visual inspection of labeling The labeling must include profile data, standard designation and identification number Notes Tooth thickness of plug gauges to Auxiliary dimension over 2 pins Auxiliary dimension over 2 measuring balls with Abbe measurement methods each over 90 in front, middle, rear Roundness deviation of the measuring pins or measuring balls: max Deviation of measuring pins or measuring balls from the nominal size: max Additionally for space width of ring gauges to measurement force < 1.5 N Measuring pins must be rubbed Size between between pins by the use of gauge blocks. Nominal size correction with the actual size of the measuring pins or measuring balls is required. The gauge blocks with the actual dimension must not have any tilt clearance between both measuring pins; it must however still be axially slidable without sticking. If the actual size of the tooth thickness / tooth space is exactly the same as the worn size, the inspection should be discontinued and the gauge no longer used. Tip Abbe measurement methods 3D measuring machines Form circle Analytical inspection machines 3D inspection machines Abbe measuring methods are not possible for odd numbers of teeth Check via roll distance or roll angle Individual form deviations: Profile Lead (=helix) Analytical inspection machines 3D inspection machines with rotary stage Profile and lead at 4 right and left flanks The measurement uncertainty of is theoretically too large, but practically not better attainable. The individual deviations may exceed those of new gauges by the amounts overleaf. Single pitch Total index Only for go gauges: index of all tooth flanks Runout As a result of the unfavorable relationship between gauge tolerances and the smallest attainable measuring uncertainty, spline gauges can only be rejected if the measured size lies outside the tolerance limits extended by the measurement uncertainty (non-conformance zone according to DIN EN ISO ). In the absence of explicit references to other regulations or agreements, agreement B applies with priority regulation according to the Frenco definition OFD 10, page 18. 9

10 Tolerances The individual deviations of spline gauges rise during wear if the wear is not uniformly distributed over all tooth flanks. If gauges have not yet reached the worn size, but the individual deviations exceed the additional tolerances with reference to the values in the new condition, these gauges are to be considered as worn and must be replaced. Permissible assumed individual deviations of spline gauges during wear up to the worn dimension over/between pins (values of a similar order of magnitude are also included in the latest editions of DIN 5480 and ISO 4156): Deviation Tolerance in addition to the new tolerances D = <D<300 Total profile deviation F + 0, ,003 Total lead deviation F + 0, ,002 Runout deviation FR + 0, ,003 Total pitch deviation FP + 0, ,003 Individual pitch deviation fp + 0, ,002 10

11 Specials Special gauges are custom manufactured according to drawings. Here there are almost no limitations. Special ring gauge Master plug gauges for spline gauge rings Setting master 11

12 Frenco Product Range High Precision Gears and Splines H Gear and Spline Gauges Master Gears, Master Wheels Artefacts, Masters Punches, Dies & Electrodes Profiled Clamping Systems Rotation Measuring Systems R Instruments with Measuring Circles Multiple Inspector Gear Flank Analysing Linear Gear Flank Analyser Rack Gear Flank Analyser Double Flank Gear Roll Inspection Gear and Spline Manufacture Gear & Spline Inspection P DAkkS -Calibration Instruments for Size Inspection Series V Measuring Pins and Ball Inserts Instruments, Rocking Type Instruments with Face Stop Instruments with Guiding Profiles Circumferential Backlash Instrument Customized Solutions Monitoring of Inspection Equipment Workpiece Inspections Analysis of Deviations Know-How-Transfer K Software Training, Seminars, Workshops Consulting and Calculations Literature and Documentations National and International Standards Frenco GmbH Gear + Spline Technology Jakob-Baier-Straße Altdorf, Germany Tel.: +49 (0) Fax: +49 (0) frenco@frenco.de